KZ650 Piston Trigger #2

Hello.
Started on a new project. It's a 1979 KZ650 that i found on Craigslist. Here are a few pictures of how it looked when i got it. From first look it's not bad but if you look closer it's a mess. It didn't run but the engine turned over and the price was right and i was itching for a new project.





Here's bunch of stuff taken apart and getting ready for powdercoating.


I modified the frame a little by adding a rear loop and shaving off a few tabs.


Made a small battery box that tucks under the seat. Sheet metal was a little to thin so i only spot welded it.



Engine has been blasted and almost ready for assembly.


I got this tractor light on ebay that was all rusted out. Cleaned it and powdercoated it. Really like the vintage glass it has.


A few shiny parts fresh from the powdercoater.


I got this vintage kawasaki enduro tank that i really like and i think i might use it on this bike. What you guys think?



This Clip-ons on ebay were a steal. They took a while to ship from china though, but the quality is great.


Rebuild old Harley progressive shocks. Getting those springs on and off was a nightmare. but i think they turned out good.


Rebuild the wheels and replaced all the bearings and spokes. Truing them took a while though. Also i converted the front rim to 18". basically front and back are identical.


So far that's where i am at right now.

I also was thinking about a bigger engine for it. I really like the GPZ750 engine, but i cant find it anywhere for a descent price. If you guys know if anyone that has one near Philadelphia area let me know.

KZ650 #2

Holy shit man, looks like you are flying through this thing! Making it look to easy. Haha!
Quite a clean start, if I must say.
I'm in.

Re: KZ650 #2

looks like a killer start, curious to how the smaller tank will look. I have a new kz400 project and I don't rly like the massive long tank on it either.

Re: KZ650 #2

Looks great so far and I really like the fit of the fuel tank. You might consider keeping the 650 engine. They are nearly as quick and fast as the 900..... not to mention it will accelerate quicker after you removed all the extra weight. I especially like the tractor light !!!!

Re: KZ650 #2

NICE!!!!! ;D

Re: KZ650 #2

Man that powder looks good, I'm in for more updates.

Re: KZ650 #2

Thanks guys. Here are a few more updates.

I really liked this Pirelli tires i found. They are 140 wide and have just enough clearance. Also fabricated the rear fender and mounted a very simple tail light.



Started shaping the seat as well.


Fitted 'All Balls' steering bearings

Re: KZ650 #2

Shit, I'd better sign up for this one before its over! I'm lovin' where this one is going!

Re: KZ650 #2

great quality so far, really digging that mini fender.

Re: KZ650 #2

Following this one. Everything looks good and detailed. I ran a similar tail light before. Led?

Sent from my SPH-L710 using Tapatalk

Re: KZ650 #2

Very cool and the small tank for sure!

Re: KZ650 #2

Powder coated oil filter screen? kick shaft seal? used rear sprocket and bolts? Interesting. :
As for more power, Wiseco has a big bore kit. Cams and exhaust systems are also available.
The carb spacing is the same for all KZ 650s thru 1100s. The right carb boots for the specific
carb have to be used. The bolt spacing is different from the 650/750 to the 900/1000/1100.
Elongating the holes on the larger 4 cyl. boots to fit the narrower 650 bolt spacing works. The
750/4 head and block will bolt on the 650 cases, but the cases will probably have to be machined
to have clearance for the 750 sleeves. The 650 and 750 are basically the same dimentions except
for bore, valve, port, and combustion chamber size. The 750 being slightly bigger on all accounts.
Some vintage racers use the 650 head on 750/810 engines claiming the 750 head is actually to
big and loses velocity.

.

Re: KZ650 #2

M.B Co said:

Following this one. Everything looks good and detailed. I ran a similar tail light before. Led?

Click to expand...

Thanks. The Led is trailer marking light. superbrightleds.com has bunch of nice options.

Nebr_Rex said:

Powder coated oil filter screen? kick shaft seal? used rear sprocket and bolts? Interesting. :
As for more power, Wiseco has a big bore kit. Cams and exhaust systems are also available.
The carb spacing is the same for all KZ 650s thru 1100s. The right carb boots for the specific
carb have to be used. The bolt spacing is different from the 650/750 to the 900/1000/1100.
Elongating the holes on the larger 4 cyl. boots to fit the narrower 650 bolt spacing works. The
750/4 head and block will bolt on the 650 cases, but the cases will probably have to be machined
to have clearance for the 750 sleeves. The 650 and 750 are basically the same dimentions except
for bore, valve, port, and combustion chamber size. The 750 being slightly bigger on all accounts.
Some vintage racers use the 650 head on 750/810 engines claiming the 750 head is actually to
big and loses velocity.

Click to expand...

Haha, the oil screen and kickshaft screen are not powdercaoted, just in the same picture. The rear sprocket is in descent shape. The powdercoater didn't disassemble the sprocket before painting, but it could of been my fault for not mentioning that. Hope it doesn't give me any problems.
I was looking into 750, but didnt know about loss in velocity. I just might stick with the current engine then unless i can find gpz750 for cheap.

Re: KZ650 #2

Few more updates.
Upholstery place did the seat in no time and it turned out pretty good.


Got the forks rebuilt and mocked up the front end. The tank is primed and ready for paint.

Re: KZ650 #2

following this one. Great progress so far!

What do you think your total cost will be when finished?

Re: KZ650 #2

Seat looks good. That's how I want mine to turn out.

Frame color is close to mine 8)


Untitled by MBCo, on Flickr

It's been a long time time since the last update. Here's some progress.
I painted the tank and experimented with using water slide paper. I designed some decals and applied them to the tank before doing the top coat. It turned out pretty good.




Finaly invested in a nice ultrasonic cleaner and rebuild the brake calipers and the carbs.



The engine rebuild was going smoothly



Until this happened.

I will admit that it was my own rookie mistake. I ended up ordering a new head and finishing up the engine.

And then this happened.


So i set the place on fire and went out for a beer. I think i got pretty lucky, the bike ended up landing on the handlebar and absorbing majority of the impact. There are a fair share of scratches but no major damage except the bent clip on bar. I think i should invest in a proper lift soon.

Next time use a wheel chock and tie it down right.

Nebr_Rex said:

Next time use a wheel chock and tie it down right.

Click to expand...

+1 on that. Lucky no one got hurt, glad damage was minimal that is a long way to fall.

Bummer, im sure you will get it in tip top shape